Shoe for a ski boot and related production method

ABSTRACT

A shoe for ski boots, including a breathable portion with a first outer layer, suitable to interface with an inner wall of an associable ski boot, and a second inner layer, at least partially overlapped and fastened to the first outer layer, said layers being at least partially pierced and comprising through holes through the same layers is provided. Advantageously, at overlapped portions of the first and second layer, the relevant holes, of the first and second layer are aligned with each other to completely pass through the succession of said layers of the breathable portion. At an inner side of the shoe, the shoe comprises a waterproofing portion shaped to allow the exit of vapour or water towards the outside of the shoe and of the containment volume and so as to prevent the entry of water or vapour from the outside of the shoe within said containment volume.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to Italian Patent Application No.BS2014A000144, filed Aug. 5, 2014, the disclosure of which is herebyincorporated by reference in its entirety.

FIELD OF APPLICATION

The present invention relates to a shoe for a boot for skiing, skitouring, telemark skiing and snowboarding, and the relative productionmethod.

BACKGROUND

As is known (FIG. 1), a ski boot consists of an external structuresuitable to contain the foot of the skier.

The external structure is typically comprised of plastic, syntheticand/or composite materials. A shoe is placed inside the externalstructure that is therefore interposed between the foot of the user andthe inner side of the external structure boot, true and proper.

The shoe can have various types of construction.

For example, shoes are known with front or rear tongue. Shoes are alsoknown with overlap construction, i.e., with overlapping or superimposedflaps.

Preferably, but not necessarily, the shoes are inserted inside theplastic structure with the possibility of being easily removed.

Usually the shoe is composed of several pieces, of characteristichardnesses and thicknesses that can be different.

The main purpose of the shoe is to provide the user comfort, thermalinsulation and water repellency. Comfort must be achieved by creating athickness of soft material that prevents direct contact between theuser's foot and the rigid shell, typically made of plastic or othermaterials, of the boot. Thermal insulation is essential in order toprovide comfort while skiing/walking and to prevent the foot frombecoming too cold. Water repellency is essential because, in the case ofinfiltration of water/snow inside the boot, it is necessary to preventthe user's foot from getting wet: in fact, in this case, the comfort andtemperature of the foot would be significantly reduced because theexchange of heat with the outside would increase.

At the same time, it is necessary to provide the shoe adequatebreathability to provide the formation and accumulation of sweat; infact, in case of accumulation of sweat, the user's comfort would declinedrastically because sweating is one of the leading causes of loss ofthermal insulation.

SUMMARY OF THE INVENTION

It is currently not possible, with the techniques of the prior art, toprovide a shoe that ensures the foot comfort, breathability, thermalinsulation and water repellency.

In fact, thermal insulation and water repellency are often mutuallyincompatible with the breathability of the foot.

In current solutions, the shoe a closed hollow space that creates sweataccumulation. Sweating, as seen, it is also one of the causes of loss ofcomfort, as it can generate blisters and reduce the thermal insulationof the shoe.

Moreover, in current solutions, water repellency is not perfectlyensured, since there are closure parts of the shoe that are simplyoverlapped, without particular systems for locking them.

An example of a known shoe can be seen in FIGS. 2 and 3, which show ashoe in open configuration, comprising an external upper that envelopesthe foot, on which are applied by gluing, seams, high-frequency welding,etc., paddings of different hardnesses, thicknesses and characteristicsin order to contain the foot in the best way possible and providemaximum comfort.

The known technique requires that there be, inside the shoe, piercedmaterials/inserts to facilitate the transpiration of sweat. In fact,various layers are realised at least partially pierced, having differentcharacteristics of materials and/or thicknesses depending on theposition that the layer/insert assumes with respect to the foot.

As seen in FIG. 3, with the known construction technique it is, however,impossible or not advantageous to superimpose several pierced layers ofsemi-finished materials. The superimposition of pierced layers has theeffect that some holes are not aligned with others and are thereforeoccluded, i.e., non-pass-through, with respect to the entire thicknessof the shoe.

Therefore, the solutions of the prior art are a compromise between thetranspiration/evaporation of the sweat of the foot and thewaterproofing/water repellency of the shoe. This compromise is not,however, able to meet the needs of more demanding users who use bootscontinuously in harsh conditions. Therefore, there is a need to solvethe drawbacks and limitations mentioned in reference to the prior art.This need is met by a shoe according to claim 1 and by a method forproducing a shoe according to claim 13.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of this invention will be moreunderstandable from the following description of its preferred andnon-limiting examples of embodiments, wherein:

FIG. 1 is a perspective view of a ski boot equipped with a shoeaccording to this invention;

FIG. 2 is a perspective view, in open configuration, of a portion ofshoe for ski boot according to a solution of the known art;

FIG. 3 is a sectional view of the portion of shoe of FIG. 2, along thesection plane III-III of FIG. 1;

FIG. 4 is a perspective view of a portion of shoe for ski boot accordingto an embodiment of this invention; FIG. 5 is a perspective view, inopen configuration, of a portion of the shoe for ski boot of FIG. 4;

FIG. 6 is a sectional view of the shoe portion of FIG. 5, along thesection line VI-VI of FIG. 5;

FIG. 7 is a sectional view of the shoe of FIG. 4, along the sectionplane VII-VII of FIG. 4;

FIG. 8 is a sectional view of the shoe of FIG. 4, along the sectionplane VIII-VIII of FIG. 4.

The elements, or parts of elements, in common between the embodimentsdescribed below will be indicated with the same reference numbers.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the above figures, the reference number 4 globallyindicates a shoe for ski boot 8.

For the purposes of this invention, it should be clarified that the termski boot must be considered in the broad sense, encompassing any type ofski, ski touring or telemark skiing or similar boot.

Typically the ski boot 8 comprises a shell 10 and a cuff 12, hinged tothe shell 10, in correspondence of the malleolus of the user's foot.

The boot 8, of any type, comprises an inner wall 16 suitable tointerface with said shoe 4, which constitutes an interface between theboot 8 and the user's foot. Said inner wall 16 defines a compartment ofthe boot suitable to contain the shoe.

The shoe 4 comprises a breathable portion 20 equipped with a first outerlayer 24, suitable to interface with an associable ski boot 8, and asecond inner layer 28, at least partially overlapped and fastened to thefirst outer layer 24.

The overlapping layers 24,28 can be fixed together, for example byfusion or gluing.

The overlapping layers 24,28 are at least partially pierced, andcomprise holes 32 that pass through the same layers 24,28. In otherwords, the holes of each layer 24,28 are not blind, but pass through athickness of the layer itself.

The fusion or gluing for the mutual fixing of the layers 24,28 is suchas not to occlude said holes 32 of the same layers.

Advantageously, at overlapping portions of the first and second layer24,28, the relevant holes 32 of the first and second layer 24,28 aremutually aligned so as to pass altogether through the succession of saidlayers 24,28 of the breathable portion 20.

According to an embodiment, said aligned holes 32 of the first andsecond layer 24,28 are mutually concentric. Preferably said alignedholes 32 of the first and second layer 24,28 are equal to each other.For the purposes of this invention, there is no preferred geometricshape for said holes 32; for example, they can be cylindrical holes.

The purpose of said holes 32 passing as a whole through the breathableportion 32 is that of ensuring the breathability of the shoe 4, inparticular from the inside to the outside, so as to prevent theaccumulation of sweat inside the shoe 4 itself.

The number and type of layers constituting the breathable portions 20can vary.

For example, in an embodiment, the shoe 4 comprises a third inner layer36 at least partially overlapped and associated to the first outer layer24 and/or second inner layer 28, said third inner layer 36 comprisingpass-through holes 32.

For the purposes of the breathability of the shoe 4, at overlappingportions of the third inner layer 36, overlapping the first outer layer23 and/or the second inner 28, the relevant holes 32 of said overlappedlayers 24,28,36 are mutually aligned so as to pass altogether throughthe succession of said layers of the breathable portion 20.

As mentioned above, the layers 24,28,36 may be different, alsocomprising for example a fourth or a fifth layer, and, preferably, eachlayer is shaped and conformed in such a way as to fulfil a function, forexample, of ergonomic padding for a specific portion of the user's foot.

The layers 24,28,36 of the breathable portion 20 are made of differentmaterials and/or have different density and/or thicknesses.

According to an embodiment, at least one of said layers 24,28,36 of thebreathable portion 20 of the shoe 4 is made of a thermo-formablematerial.

Thermo-formable material means a material suitable to be formed underthe action of heat so as to maintain the conformation also following itssubsequent cooling. The shoes are thermo-formed by fitting the shoe tothe user: in this way, the shoe can actually take the shape of theuser's foot and therefore can be shaped to measure.

In order for the thermoforming to take place in a comfortable manner, itis necessary that the material forming the layers 24,28,36 isthermo-formable at a sufficiently low temperature so that they can beheated, and thus thermo-formed, while the user is wearing the shoewithout being his being burned. According to an embodiment, on the firstouter layer 24, on the side opposite to the second inner layer 28, thereis applied a pierced and breathable upper 40.

The upper 40, which therefore interfaces with the inner wall 16 of theboot 8, has the function of protecting the shoe 4 from rubbing againstsaid inner wall 16 without, at the same time, affecting thebreathability of the shoe 4 in any way.

The upper 40 thus has the function of protecting the shoe from wear dueto rubbing with the external structure.

This material/layer can be added after the forming of the raw materialconstituting the breathable portion 20 (in roll or sheet) or it can bedone by subsequent overlapping (sock type).

At an inner side 44 of the shoe 4, directly facing a containment volume48 of a user's foot delimited by the shoe itself, the shoe 4 comprises awaterproofing portion 52 shaped so as to allow the exit of water orvapour towards the outside of the shoe 4 and of the containment volume48 and so as to prevent the entry of water or vapour from the outside ofthe shoe 4 within said containment volume 48.

For example, the waterproofing portion 52 is formed in such a way as tobe folded and sealed as a bag, having a front access portion 56 so as tocover an associable user's foot at least up to the height of an ankle ofsaid foot.

According to an embodiment, said waterproofing portion 52 is folded andsealed by seams and wherein said seams are waterproofed.

For example, said waterproofing portion 52 comprises fabric such asGORE-TEX® or the like.

The waterproofing portion 52 could be associated with at least one ofsaid layers 24,28,36 of the breathable portion 20 of the shoe 4 by(specify: gluing?).

By interposing, between the foot and the breathable portion 20 of theshoe 4, a membrane with a water-repellent technology (for example,GORE-TEX®), one obtains a perfect breathability of the foot whileensuring total water repellency.

It is clear that the shoe 4 is composed of several parts, such as forexample an insole 60, which is also preferably provided with holes 32and suitable to realise a comfortable support for the sole of the foot.Moreover, the shoe may include a tongue 64 and an upper structure 68suitable to embrace the tibial zone of the user. The shoe 4 can alsocomprise further inserts or padding 72 suitable to absorb impacts andrubbing with parts of the foot, such as for example the malleolus or thetip of the foot, which is particularly stressed in use.

We will now describe the method of producing a shoe for ski bootaccording to this invention.

Said method comprises the steps of:

-   -   preparing a breathable portion 20 comprising a first outer layer        24, suitable to interface with an associable ski boot 8, and a        second inner layer 28, at least partially overlapped and        fastened to the first outer layer 24,    -   piercing holes in said first and second layer 24,28, at least at        the mutually overlapping portions, so as to make aligned holes        32 through the same overlapping layers of the breathable portion        20,    -   preparing, at an inner side 44 of the shoe 4, directly facing a        containment volume 48 of a user's foot delimited by the shoe 4,        a waterproofing portion 52 shaped so as to allow the exit of        vapour or water towards the outside of the shoe 4 and of the        containment volume 48 thereof and so as to prevent the entry of        water or vapour from the outside of the shoe 4 within said        containment volume 48.

For example, the step of piercing the breathable portion 20 can beeasily performed by subjecting the breathable portion in openconfiguration, and thus planar, to the action of a roller provided withexternal pins suitable to pierce the breathable portion: in this wayeach pin has the possibility to fully pierce the breathable portion 20through the overlapping of layers 24,28,36 that compose it, ensuringthat the holes 32 are aligned with each other. In this way, theeffective breathability of said breathable portion 20 is ensured due tothe fact that the openness of the holes 32 is always ensured and thereis no risk that the holes may be offset from each other so as tomutually occlude one another in the transition from one layer toanother.

According to a further embodiment, the method also comprises the step ofsuitably shaping the overlapping and mutually associated layers 24,28,36of the breathable portion 20 so to obtain a thickness variation of thebreathable portion 20 according to the portion of the user's footintended to come into contact with it,

-   -   associating the waterproofing portion 52 to the breathable        portion 20.

The step of shaping the overlapping layers 24,28,36 involves, forexample, a step of removing the excess material, or skiving of thelayers, according to known technique. However, to date, this skivingtechnique has never been applied to a shoe having a breathable portion20 completely or partially pierced that envelopes the foot and iscomposed of multiple thicknesses and densities.

This type of construction, when applied to the known technique,undoubtedly presents an advantage of breathability.

As can be appreciated from the description, the shoe according to theinvention allows overcoming the drawbacks presented in the prior art.

In particular, the shoe according to the invention allows meeting theuser's needs in terms of breathability of sweat at the same timecomfort, thermal insulation and waterproofing from the outside. In fact,the presence of multiple overlapped and pierced layers with aligned,pass-through holes, first allows a good breathability of the foot andthus allows the sweat the possibility of exiting through said alignedand pass-through holes.

At the same time, the presence of a waterproofing portion, such as aninner water-repellent membrane, ensures the water repellency of theshoe, i.e., it prevents water from penetrating from the outside of theshoe and coming in contact with the user's foot.

All the comfort characteristics of the shoe remain unchanged in terms ofinner/outer layers and padded portions so as to absorb the impact of thefoot against the boot.

The shoe is light overall and comfortable to wear.

The method of producing the shoes is also simple, fast and inexpensiveto implement.

A person skilled in the art, in order to satisfy contingent and specificneeds, may make numerous modifications and variations to the shoe andthe shoe production method described above, all however contained withinthe scope of the invention as defined by the following claims.

1. A shoe for ski boots, comprising: a breathable portion with a firstouter layer, suitable to interface with an inner wall of an associableski boot, and a second inner layer, at least partially overlapped andfastened to the first outer layer, said layers being at least partiallypierced and comprising through holes through the same layers, wherein,at overlapping portions of the first and second layer, the relevantholes of the first and second layer are mutually aligned so as to passaltogether through the succession of said layers of the breathableportion, and wherein, at an inner side of the shoe, directly facing acontainment volume of a user's foot delimited by the shoe, the shoeincludes a waterproofing portion shaped so as to allow the exit ofvapour or water towards the outside of the shoe and of the containmentvolume and so as to prevent the entry of water or vapour from theoutside of the shoe within said containment volume.
 2. The shoeaccording to claim 1, wherein said aligned holes of the first and secondlayer are mutually concentric.
 3. The shoe according to claim 1, whereinsaid aligned holes of the first and second layer are equal to eachother.
 4. The shoe according to claim 1, wherein the shoe furthercomprises a third inner layer at least partially overlapped andassociated to the first outer layer, and/or the second inner layer, saidthird inner layer including through holes, wherein at portions of thethird inner layer overlapping the first outer layer, and/or the secondinner layer, the corresponding holes of the overlapping layers aremutually aligned so as to pass altogether through the succession of saidlayers.
 5. The shoe according to claim 1, wherein said layers of thebreathable portion have different materials, and/or thickness and/ordensity.
 6. The shoe according to claim 1, wherein on the first outerlayer, on the side opposite to the second inner layer, there is applieda pierced and breathable upper.
 7. The shoe according to claim 1,wherein the waterproofing portion is formed in such a way as to befolded and sealed as a bag, having a front access portion so as to coveran associable user's foot at least up to the height of an ankle of saidfoot.
 8. The shoe according to claim 1, wherein the waterproofingportion is folded and sealed by seams and wherein said seams arewaterproofed.
 9. The shoe according to claim 1, wherein thewaterproofing portion comprises GORE-TEX® type fabric.
 10. The shoeaccording to claim 1, wherein the waterproofing portion is associatedwith at least one of said layers of the breathable portion of the shoeby gluing.
 11. The shoe according to claim 1, wherein at least one ofsaid layers of the breathable portion of the shoe is made of athermo-forming material.
 12. A ski boot comprising a shoe according toclaim 1, said shoe being accommodated inside a compartment of the bootdelimited by an inner wall of the boot so as to face the first outerlayer of the shoe to said inner wall of the boot.
 13. A method ofmanufacture of a shoe for a ski boot comprising the steps of: preparinga breathable portion comprising a first outer layer, suitable tointerface with an associable ski boot, and a second inner layer, atleast partially overlapped and fastened to the first outer layer,piercing holes in said first and second layer, at least at the mutuallyoverlapping portions, so as to make aligned holes through the sameoverlapping layers of the breathable portion, preparing, at an innerside of the shoe, directly facing a containment volume of a user's footdelimited by the shoe, a waterproofing portion shaped so as to allow theexit of vapour or water towards the outside of the shoe and of thecontainment volume thereof and so as to prevent the entry of water orwater vapor from the outside of the shoe within said containment volume.14. The method of manufacture of a shoe for a ski boot according toclaim 13, further comprising the steps of: suitably shaping theoverlapping and mutually associated layers of the breathable portion soto obtain a thickness variation of the breathable portion according tothe user's foot portion intended to come into contact therewith, andassociating the waterproofing portion to the breathable portion. 15.Method of manufacture of a shoe for a ski boot according to claim 13,including the step of making a shoe such that it has: a breathableportion with a first outer layer, suitable to interface with an innerwall of an associable ski boot, and a second inner layer, at leastpartially overlapped and fastened to the first outer layer, said layersbeing at least partially pierced and comprising through holes throughthe same layers, wherein, at overlapping portions of the first andsecond layer, the relevant holes of the first and second layer aremutually aligned so as to pass altogether through the succession of saidlayers of the breathable portion, and wherein, at an inner side of theshoe, directly facing a containment volume of a user's foot delimited bythe shoe, the shoe includes a waterproofing portion shaped so as toallow the exit of vapour or water towards the outside of the shoe and ofthe containment volume and so as to prevent the entry of water or vapourfrom the outside of the shoe within said containment volume.